Ring, Pinion and Bearings
COMPONENT NOTES AND INFORMATION
- Hypoid transmission fluid
Drain; till as far as lower edge of oil filler bore.
Tightening torque of oil screw plug (51) 50 Nm.
- Rear axle center piece (50)
Clamp in jig; release from jig.
Jig Tool No. 129 689 00 31 00.
- Rear axle end cover (54)
Detach, attach.
Clean sealing surface and coat with sealant.
Tightening torque of collared bolt (56b) 55 Nm.
Torque wrench tool No. 001 589 66 21 00
- Breather (65)
Replace, 30 Nm.
- Circlips (30a)
Remove. install, replace
Hook tool No. 116 589 01 62 00
- Connecting flanges (33 and 33a}
Remove, install.
Adjust play of connecting flanges (33 and 33a),
- Side bearing covers (27 and 27b]
Remove and install by unscrewing and screwing in Allen bolts (27a).
Tightening torque 20 Nm.
Tools For Adjusting backlash and expansion.
Contact blocks tool No. 201 589 01 63 00
Contact arm tool No.126 589 08 21 00
Torque wrench tool No. 001 589 66 21 00
Backlash meter tool No. 140 589 08 21 00
- Differential housing (12a)
Remove, install
- O-rings (25)
Remove, install, replace.
- Shims (26)
Remove, install and mark together with bearing covers (27 and 27b) for left and right sides
- Radial oil seals (32a)
Press out, press in, replace.
Drift tool No. 140 589 03 15 00
- Tapered roller bearing inner races (11a)
Pull off, mark and press on.
Puller tool No. 123 589 08 33 00
Drill tool No. 140 589 09 15 00
- Tapered roller bearing outer races (11)
Pull out, mark and press in.
Tools For Procedure
Puller tool No. 000 589 88 33 00
Puller arms tool No. 126 589 00 34 00
Thrust piece tool No. 124 589 02 34 00
Drift tool No. 140 589 09 15 00
- Crown wheel (47a)
Remove, install.
Mark position of crown wheel with respect to differential housing (12a), and press off carefully.
Heat crown wheel to 75-85°C prior to installing.
Replace crown wheel bolts.
Tightening torque of serrated locking bolts 140 Nm.
Torque wrench tool No. 001 589 67 21 00
- Twelve-point collared nut (40a)
Slacken, tighten, replace and lock.
Tightening torque 120-130 Nm.
30 mm socket wrench attachment tool No. 126 589 02 09 00
Pin Wrench tool No. 129 589 01 07 00
Adapter tool No. 100 589 02 59 00.
Torque wrench tool No. 001 589 66 21 00
- Propeller flange (41a)
Remove, install.
Mark position of propeller flange with respect to bevel drive pinion.
Check contact surface for radial oil seal for wear, and replace propeller flange if necessary.
Pull off if necessary using puller tool No. 129 589 01 33 00.
- O-ring (41b)
Replace.
- Radial oil seal (42a)
Press out, press in, replace.
Drift tool No. 140 589 02 15 60
- Oil slinger (43c)
Press off, press on, replace.
Drift tool No. 140 589 02 15 00
- Twelve-point collared nut (43b)
Slacken, tighten, replace and lock.
Tools needed for adjusting friction torque.
Socket wrench attachment WAF 41, 140 589 01 09 00
Socket wrench attachment 3/4", 140 589 00 08 00
Torque meter, 001 589 02 59 00
Adapter, 100 589 02 59 00
Torque wrench, 001 589 74 21 00
- Bevel drive pinion (47)
Remove, install and check adjustment.
Use two arm puller 000 SB9 65 33 00 to press bevel drive pinion out of housing.
When installing, support bevel drive pinion with removal installation tool 140 589 10 43 00.
- Tapered roller bearing inner race (43)
Take off, push on.
Press on using sleeve tool No. 140 589 04 15 00.
- Tapered roller bearing outer races (43 and 46)
Remove. install.
Remove shim, install and measure.
Removal/installation tools
Thrust piece
Thrust piece
Puller
- Spacer sleeve (44) with contact washers (48)
Remove, install.
Replace spacer sleeve and contact washers
- BS rotor (49)
Pull off, press on, except rear axle center piece with ASR.
To press on, use sleeve tool No. 140 589 04 15 00.
Puller tool No. 000 589 88 33 00 with arms tool No. 116 589 12 33 00
- Tapered roller bearing inner race (46)
Pull off bevel drive gear 147), press on.
Pulling device001 589 35 33 00
Extension tool No. 000 589 35 34 00
Collet chuck tool No. 140 589 02 34 00
Open-end wrench WAF 55x65 tool No. 140 589 00 01 00
To press on, use sleeve tool No. 140 589 04 15 00 without internal sleeve.
- Rear axle center piece with ASR
- Shim (L6/3c) for speed sensor
Remove.
Calculate check distance "a", determine gauge of shim and secure with self-adhesive paper.
PROCEDURES
Assembly And Adjustment
NOTE:
^ Each bevel drive pinion and crown wheel of a set is marked with a serial number (arrows) which is stamped on both parts.
^ In addition. the bevel drive pinion is always marked with the specific distance (with the sign + or -) for this crown wheel/pinion that is to be set between the two gears.
^ A data sheet must be used to calculate the gauge of the shim required to adjust the bevel drive pinion.
^ A specimen data sheet can be found at the end of this operation number. The measurement and calculation procedures of the example given in this data sheet are described in detail on page two of the example. Refer to Rear Axle Gears Adjustment Form. Adjustments
1 Press large tapered roller bearing (46) onto bevel drive pinion (47) using sleeve (047) 140 589 04 15 00 part 01.
- To do this, first remove inner sleeve, part 02.
2 Press on ABS rotor (49) using sleeve (047) 140 589 04 15 00 part 1 and inner sleeve (847a) part 2, except on rear axle center pieces with ASR.
NOTE: The number of teeth on the rotor must correspond with the rear axle ratio (see Specifications).
3 Screw gauge and gauge holder (056) 363 589 02 21 00 (remove magnetic stand) onto measuring base (031) 140 589 16 23 00.
4 With approx. 3 mm preload, first set gauge to "0" on gauging member (051b) 140 589 07 21 00 part 01.
5 Press outer bearing race (46) onto roller cage of bevel drive pinion (47) and add magnetic plate (020) 140 589 25 63 00.
- Insert bevel drive pinion (47) into measuring base (031) and measure height of bevel drive pinion with bearing and magnetic plate.
6 Read off difference between height of gauging member "B1- and height of bevelled end of drive pinion "B" and enter the value calculated (e.g. 1.46 mm) beside section 1 in the data sheet.
7 Enter fundamental deviation :a" of bevel drive pinion (see arrow, + or -) beside section 2 (e.g. -0.04 mm) in the data sheet.
8 According to the sign of the number on the bevel drive pinion, either add (+) or subtract (-) values from sections 1 and 2.
9 Insert gauging member (051b) 140 589 07 21 00 part 01 into rear axle housing and screw together with retaining piece 140 589 07 21 00 part 02.
10 Install gauge with gauge holder (030) 111 589 08 23 00 in adjustment gauge (035) 115 589 05 21 00 and set to "0" with 3 mm preload.
11 Clean contact surfaces of bearing covers on sides of rear axle housing.
12 Insert measuring bracket (030a) 116 589 01 21 00 part 01 together with gauge holder (030) and gauge into left hand bore in rear axle housing and screw in place.
13 Read off difference between set gauge distance and end face of gauging member, and enter beside section 3 of the adjustment form, in either the positive or negative direction (e.g. - 0.55 measured, therefore in negative direction).
NOTE:
^ The direction positive (+) or negative (-) refers to the direction of rotation of the gauge needle
^ Any counterclockwise deviation from the zero position is in the negative direction, clockwise is the positive direction.
14 Add (+) or subtract (-) the subtotal from sections 1 and 2 of the form with the value from section 3.
- The result obtained gives the thickness of the shim.
Example:
Section 1 = 1.46
Section 2 = + 0.00
= - 0.04 _____
Subtotal = 1.42
Section 3 =
Negative Direction = + 0.55
Positive Direction = - 0.00 _____
Thickness of Shim "S = 1.97 _____
15 Remove measuring bracket and gauging member from rear axle housing.
16 Insert shim (45) of calculated thickness "S" into rear axle housing (see example).
NOTE:
^ Only tempered shims must be used
^ Shims are available in various thickness (see Specifications)
^ If necessary, a shim should be ground down as required.
17 Pull outer races of front (43) and rear (46) tapered roller bearings into rear axle housing using puller (060a-d) 140 589 0143 00.
CAUTION: Ensure that the outer races do not tilt during installation.
18 Add one contact washer 148) to each side of new spacer sleeve (44) and push onto bevel drive pinion.
19 Install bevel drive pinion in rear axle housing and support with removal/installation tool (038) 140 589 10 43 00 by carefully screwing in threaded spindle by hand as far as end face of bevel drive pinion.
20 Push tapered roller bearing inner race 143) onto bevel drive pinion and press in with sleeve (047) 140 589 04 15 00.
21 Screw on new inner twelve point collared nut (43b).
CAUTION: Coat the contact collar of the twelve-point collared nut with Molycote grease.
22 Push socket wrench attachment WAF 41 (043) 140 589 01 09 00 and 3/4 inch socket wrench attachment (043a) 140 589 00 08 00 onto bevel drive pinion.
23 Carefully tighten twelve-point collared nut using torque wrench 001 589 74 21 00 until the specified friction torque is attained (see table "Friction torque for bevel drive pinion bearing:).
CAUTION: When tightening the twelve-point collared nut, turn the bevel drive pinion several times and gently tap the rear axle housing to ensure that the tapered rollers properly engage in their tracks.
24 Remove removal/installation tool with socket wrench attachment WAF 41 from rear axle housing.
25 To check installation, attach torque meter (018) 001 589 48 21 00 with adapter (019) 100 589 02 59 00 to 3/4 inch socket wrench attachment (043a) 140 589 00 08 00 and crank bevel drive pinion.
CAUTION: To measure the friction torque, the bevel drive pinion must be cranked by hand at approx. 50-60 revs min.
NOTE:
^ The tapered roller bearings (43 and 46) of the bevel drive pinion (47) must be installed with a certain preload.
^ This permanent preload is obtained by compressing the spacer sleeve (44) located between the inner bearing race of the front tapered roller bearing and the bevel drive pinion while tightening the twelve-point collared nut (43b).
^ If the friction torque when the bevel drive pinion slips is too low (i.e. if the preload is insufficient), the twelve-point collared nut (43b) should be tightened further slightly.
^ If the specified friction torque is exceeded, the bevel drive pinion must be removed again and a new spacer sleeve (44) installed.
^ The friction torque must never be reduced by slackening the twelve-point collared nut, or the preload of the tapered roller bearings will be insufficient.
^ This would result in play in the bevel drive pinion during driving and possible noises in the rear axle drive unit.
26 Again install measuring equipment (040) 116 589 01 21 00 part 01, together with gauge holder (030) 111 589 08 23 00 and gauge, in left-hand bore in rear axle housing to check the setting.
- Place magnetic plate (020) 140 589 25 63 00 on end face of bevel drive pinion to measure adjustment distance "A".
NOTE:
^ The deviation of the crown wheel pinion in this example is -0.04 mm from the basic dimension in the negative direction and corresponds to the value stamped on the end face of the bevel drive pinion.
^ The permissible fundamental deviation of the adjustment distance "A" must not be exceeded by more than 0.01 mm in the positive and 0.02 mm in the negative direction.
^ If the deviation is larger, the installed shim must be re-ground or a new shim of the corresponding thickness must be installed
^ It is absolutely essential, however, that a new spacer sleeve for the tapered roller bearings be installed.
27 Remove measuring equipment, magnetic plate and gauge with holder from rear axle housing.
28 Stake the twelve-point collared nut (43b) into one of the two grooves in the bevel drive pinion so that there is no gap between the groove and locking tab (detail, top left).
CAUTION: Do not deal any strong blows in the axial direction.
29 Push on new oil slinger (43c)
- Press onto collar of twelve-point nut using drift (042a) 140 589 02 15 00.
30 Coat lip of rubber/metal radial oil seal (42a) with hypoid transmission fluid and press into rear axle housing using drift (042a)
31 Replace O-ring (41b) in 4-arm propeller flange (if equipped).
32 Push propeller flange onto bevel drive pinion noting the alignment marks made earlier on propeller flange and bevel drive pinion.
33 Screw on new twelve-point collared nut
- Push pin wrench (040) 129 589 01 07 00 and 30 mm socket wrench attachment (040a) 126 589 02 09 00 onto propeller flange (41a)
- Tighten twelve-point collared nut to: 120-130 Nm.
34 Stake the twelve-point collared nut (40a) into one of the two grooves in the bevel drive pinion so that there is no gap between the groove and locking tab (detail, top left).
- Dimension "a," approx. 8 mm
- Dimension "b," approx. 4 mm
CAUTION: Do not deal any strong blows in the axial direction.
35 Press tapered roller bearing inner race (tea) into side bearing covers (27 and 27b) using drift (01 la) 140 589 09 15 00.
36 Press in radial oil seal (32a) using drift (032a) 140 589 03 15 00
- To do this, lay bearing cover (27b) on removal/installation tool (034a) 129 589 02 43 00 part 01.
37 Place previously removed shims (26) on bearing covers (27b) and insert new O-rings (25) into grooves in bearing cover.
Adjusting Backlash
NOTE:
^ The backlash of crown wheel/pinion and the necessary preload in the tapered roller bearings for the differential are adjusted by installing shims between the bearing covers and the rear axle housing.
^ The shims are available in various thickness.
^ To install, first reinstall the previously removed bearing cover and shims on the appropriate side to obtain a provisional basic setting.
38 Dismantle and assemble differential as required, refer to Differential Gears and Ring Gear Carrier.
39 Carefully clean crown wheel and seat on differential housing
- Heat crown wheel (47a) to 75-85°C and place on differential housing
- If appropriate, note the alignment marks made earlier on the crown wheel and differential housing (arrow).
- If the crown wheel will not go on the differential housing, ease it into place by tapping with a plastic mallet.
CAUTION:
^ When installing a new differential housing or if using new crown wheel bolts, note the length of the crown wheel bolts.
^ For differential housings with 8 mm thick contact flange (distance "B"), use crown wheel bolts 20 mm long.
40 Tighten new serrated locking bolts (13a) to: 140 Nm in a crosswise pattern
- Torque wrench 001589 67 21 00.
- As Always replace crown wheel bolts when they have been used once.
41 Press tapered roller bearing outer race (11a) into differential housing (12a) using drip (011a) 140 589 09 15 00.
42 Lightly coat circumference of O rings and bearing cover (27a) with hypoid transmission fluid.
43 Insert differential into rear axle housing and push in both side bearing covers (27a) as far as they will go.
CAUTION: Do not damage the O-rings when installing the bearing covers.
NOTE:
^ Installed position of the side bearing covers.
^ The ABS bearing covers are marked with the word UNTEN (= down).
^ ASR bearing covers must be installed with the speed sensor connection pointing upwards
^ This information refers to the installed position of the rear axle center piece in the vehicle.
Arrangement With ASR:
NOTE: If the side bearing covers stick in the bore in the rear axle housing, ease them into place by tapping with a plastic mallet (arrows).
44 Screw contact blocks (050a) 201 589 01 63 00 for contact arm (050) 126 589 08 21 00 to left and right sides of sealing surface on rear axle housing.
45 Place contact arm for measuring housing expansion and gauge on contact blocks and set gauge to "0" with approx. 3 mm preload.
46 Screw in all Allen bolts (27a) on side bearing covers.
- Tighten to: 20 Nm
- Torque wrench 001 589 66 21 00.
47 Use contact arm again
- The required expansion (spread) of the rear axle housing, and thus the correct preload for the tapered roller bearings on the differential, is obtained when the expansion measures between 0.15 and 0.20 mm.
48 Install backlash meter (0371 140 689 08 2100 with bushing in left-hand bore in differential housing and secure.
49 By moving the gauge holder or the crown wheel, measure the backlash at four points referred to the circumference of the crown wheel.
- The smallest measurement applies.
- The backlash must measure 0.08-0.14 mm.
- During each measurement, hold the bevel drive pinion securely by the propeller flange.
NOTE:
^ The adjustment of the tapered roller bearings and the crown wheel/pinion is correct when both the spread (expansion) of the rear axle housing and the backlash are within the nominal ranges.
^ If these values are not attained, the adjustment must be repeated using thicker or thinner shims as required (see Specifications).
Example 1:
- If the backlash is correct but the expansion of the rear axle housing is too small, then shims of equally smaller thickness must be installed on both side bearing covers.
Example 2:
- If the expansion is correct but the backlash is excessive, then a shim which is thicker by the missing amount must be installed on the lefthand side, and a shim which is thinner by the same amount on the right-hand side.
- If the backlash is insufficient, proceed in the reverse sequence.
50 Remove contact blocks.
51 Pull deep-groove ball bearing from connecting flange (33a).
- Use pulling device 001 589 36 33 00, collet chuck 140 589 00 34 00 and open-end wrench WAF 55x65 mm 140 589 00 0100.
52 Press deep groove ball bearing (33c) all the way onto flange using a suitable tube (033c).
53 Push left and right connecting flanges (33a) into rear axle shaft gear.
54 Press new circlip (30a) of same thickness as that previously installed between connecting flange and rear axle shah gear.
55 Check axial play between connecting flange and rear axle shaft gear.
- There must be no perceptible play.
- The circlip should still be free to rotate in the groove.
- If necessary, install a thicker or thinner circlip as required (see Specifications).
CAUTION: Replace the circlip if it has been user, once.
56 Clean sealing surfaces on rear axle end cover (54) and rear axle housing, and coat with sealant.
57 Install rear axle end cover.
- Tighten multi-point Allen bolts to: 55 Nm.
- Torque wrench 001 589 66 21 00
58 Remove rear axle center piece from the jig.
Rear Axle Center Piece With ASR
59 Measure distance "a" between contact surface of speed sensor and head dia. of ASR rotor (see detail) using commercially available depth gauge (033d).
- Determine thickness of shim from table (see Specifications) and stick appropriate shim onto contact surface with self adhesive paper.
All Axles
60 Fill with hypoid transmission fluid up to lower edge of oil filler bore (for oil type and capacity, see Specifications).
- Tighten screw plug to: 50 Nm.
61 Replace breather (55) on rear axle .
- Tighten to: 30 Nm.